JP3052291B1 - Method of manufacturing decorative molded products at the same time - Google Patents

Abstract

An object of the present invention is to provide a method for manufacturing a simultaneously decorated decorative molded product that can obtain a beautiful simultaneously molded decorative molded product by bringing a decorative sheet into close contact with a mold even if the shape of the molded product is not flat. I do. SOLUTION: A decorative sheet 1 is arranged by a decorative sheet conveying member 11 on a cavity mold 2 in which a cavity surface 6 is formed in a three-dimensional shape, and then the front end of the decorative sheet 1 is fixed by an end face clamp member 9, Next, the decorative sheet conveying member 1
1 is retracted, the feeding of the decorative sheet 1 is fixed, and the fixing of the decorative sheet 1 by the end face clamp member 9 is released. Then, the decorative sheet 1 is fixed by the three-dimensional frame-shaped clamp member 4 along the cavity surface 6 of the cavity mold 2. The decorative sheet 1 is fixed to the cavity mold 2, then the core mold 3 is closed, and the molding resin 15 is injected into the mold, and the decorative sheet 1 and the molding resin 15 are formed.
Are integrated with each other to obtain a simultaneously decorated decorative molded product 16.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a simultaneously decorated decorative molded article which can be used for interior parts for automobiles, panels for electric appliances, and the like.

[0002]

2. Description of the Related Art As a method of decorating the surface of an article, there are an insert molding method using a decorative sheet and a molding simultaneous transfer method. The insert molding method is to supply an insert material with a pattern layer etc. formed on a base sheet into an injection molding die, form a three-dimensional molded product, and simultaneously bond the insert material to the molded product It is a way to decorate.

In the simultaneous molding transfer method, a transfer material having a transfer layer comprising a release layer, a pattern layer, an adhesive layer, etc. formed on a base sheet is sandwiched in a molding die, and the resin is injected and filled in the die. At the same time as cooling to obtain a resin molded product, the transfer material is integrally bonded to the surface of the molded product, and then the base sheet is peeled off.
This is a method in which the transfer layer is transferred to the surface of the transfer object to perform decoration.

When a decorative sheet is fixed to a cavity surface having a complicated shape by using such a decorative sheet as an insert material or a transfer material, a frame-like shape having a shape along the cavity surface is required. Using a three-dimensional frame-shaped clamp member, the periphery of the decorative sheet is fixed so that the decorative sheet can be stretched uniformly without displacement.

[0005]

However, when the cavity surface of the cavity mold is formed in a three-dimensional shape to obtain a simultaneously-decorated molded product having a shape such as an angle material, the surroundings of the decorative sheet are reduced. Even if it is attempted to fix with a frame-shaped three-dimensional frame-shaped clamp member along the cavity surface, the decorative sheet will not be fixed by the three-dimensional frame-shaped clamp member, and the decorative sheet will not float along the cavity surface. In some cases, both sides of the decorative sheet slipped through the frame of the three-dimensional frame-shaped clamp member, and even the periphery of the decorative sheet could not be fixed.

As described above, when the decorative sheet is floating in the frame of the three-dimensional frame-shaped clamp member, the volume of the cavity space formed between the decorative sheet and the mold becomes large, which is necessary for vacuum forming. In some cases, the decorative sheet takes extra time, and the decorative sheet is heated more than necessary due to a delay in the vacuum forming time, causing the decorative sheet to wrinkle.

[0007] Accordingly, the present invention is to solve the above-mentioned problems and to obtain a beautiful molded simultaneous decorative molded article by bringing the decorative sheet into close contact with the mold even if the molded article is not flat. It is an object of the present invention to provide a method for producing a simultaneously decorated decorative molded article that can be formed.

[0008]

Means for Solving the Problems In order to achieve the above object, the method for producing a simultaneously decorated decorative molded article according to the present invention is constituted as follows.

That is, according to the method of manufacturing a simultaneously decorated decorative molded article of the present invention, a decorative sheet is disposed by a decorative sheet conveying member on a cavity mold having a three-dimensional cavity surface, and then the decorative sheet is formed. The leading end is fixed by the end face clamp member, then the decorative sheet conveying member is retracted, then the feeding of the decorative sheet is fixed, and the fixation of the decorative sheet by the end face clamp member is released. The decorative sheet is fixed to the cavity mold by the three-dimensional frame-shaped clamp member, then the core mold is closed, the molding resin is injected into the mold, and the decorative sheet and the molding resin are integrated to form a decorative simultaneous molded article. It was configured to obtain

In the above invention, the decorative sheet may be formed by vacuum forming or pressure forming so that the decorative sheet follows the cavity surface.

In the above invention, the decorative sheet may be constituted by an insert material.

In the above invention, the decorative sheet may be a transfer material.

[0013]

Embodiments of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a perspective view showing one embodiment of a molding and decorating mold used in the method of manufacturing a molded and decorated product of the present invention. 2 to 9 are cross-sectional views showing one step of the method for manufacturing a simultaneously decorated decorative molded product according to the present invention. FIG.
FIG. 1 is a perspective view showing an embodiment of a simultaneously molded and molded article obtained by the method of manufacturing a simultaneously decorated and molded article of the present invention. In the drawing, 1 is a decorative sheet, 2 is a cavity type, 3 is a core type, 4 is a three-dimensional frame-shaped clamp member, 5 is a three-dimensional frame-shaped clamp member driving source, 6 is a cavity surface, 9 is an end surface clamp member, and 10 is An end surface clamp member driving source, 11 is a decorative sheet conveying member, 12 is a decorative sheet cutting means, 13 is a suction hole, 14 is a heating means, 15 is a molding resin, and 16 is a simultaneously decorated decorative molded product.

In the method for manufacturing a simultaneously-decorated molded product according to the present invention, the decorative sheet 1 is placed on the cavity mold 2 having the cavity surface 6 formed in a three-dimensional shape by the decorative sheet conveying member 11.
Is arranged, and then the front end of the decorative sheet 1 is fixed by the end face clamp member 9, then the decorative sheet transport member 11 is retracted, and then the feeding of the decorative sheet 1 is fixed and the decorative sheet by the end face clamp member 9 is fixed. 1 is released, and then the decorative sheet 1 is fixed to the cavity mold 2 by the three-dimensional frame-shaped clamp member 4 along the cavity surface 6 of the cavity mold 2, then the core mold 3 is closed and the molding resin is injected into the mold. In this method, the decorative sheet 1 is integrated with the molding resin 15 to obtain a simultaneously molded decorative molded product 16 (see FIGS. 1 to 9).

The cavity mold 2 has a three-dimensional shape such as a groove on the cavity surface 6 as in the case of forming an angle material or the like, and is formed in a shape in which the decorative sheet 1 can be easily extended ( (See FIG. 1).

The three-dimensional frame-shaped clamp member 4 is
Is formed in a three-dimensional frame shape such as a kamaboko shape which follows the three-dimensional shape of the cavity surface 6 of the cavity mold 2 in order to fix the periphery of the cavity mold 2.

The three-dimensional frame-shaped clamp member 4 is
In order to be able to move in and out, a three-dimensional frame-shaped clamp member driving source 5 such as a hydraulic cylinder or an air cylinder may be used (see FIG. 2). For example, a three-dimensional frame-shaped clamp member driving source 5 is provided on both side surfaces of the cavity mold 2, and the three-dimensional frame-shaped clamp member 4 can be brought out by pushing out a rod by the three-dimensional frame-shaped clamp member driving source 5 (FIG. 2 to 5), the three-dimensional frame-shaped clamp member 4 can be brought into the on state by retracting the rod (FIG. 6).
To 7).

The three-dimensional frame-shaped clamp member 4 may be divided into a plurality of frames instead of a single frame, and each of the divided frames may be individually driven. For example, the lower side of the three-dimensional frame-shaped clamp member 4 may be divided separately, and the lower side of the three-dimensional frame-shaped clamp member 4 may be shared as the end face clamp member 9. Further, the three-dimensional frame-shaped clamp member 4 is divided into two right and left parts, and the divided three-dimensional frame-shaped clamp member 4 is divided into two parts.
Are configured to open diagonally outward from the cavity mold 2 so that when the decorative sheet 1 is carried in, the end of the decorative sheet 1 is caught by the three-dimensional frame-shaped clamp member 4 and breaks. Can be prevented.

Further, the molding and decorating mold may be provided with a vacuum mechanism, a heating means 14 for the decorating sheet 1 and the like, similarly to the conventional molding and decorating mold.

As the decorative sheet 1, an insert material or a transfer material can be used.

The insert material is one in which a pattern layer or the like is formed on a base sheet.

Examples of the base sheet include polyethylene terephthalate film, acrylic film, polypropylene film, thermoplastic elastomer film, polycarbonate film, polyamide film, acrylonitrile-butadiene-styrene film, acrylonitrile-styrene film, polystyrene film, polyurethane film, and the like. A sheet used as a base sheet of a normal insert material, such as a composite of the above sheets, can be used.

The design layer is a layer for decorating the surface of the simultaneously molded decorative molded product 16, and specifically includes, for example, designs such as characters and symbols, solid designs, and patterns such as wood patterns and stone patterns. Can be The design layer is usually formed as a printing layer.
As a material of the printing layer, a resin such as a polyvinyl resin, a polyamide resin, a polyester resin, an acrylic resin, a polyurethane resin, a polyvinyl acetal resin, a polyester urethane resin, a cellulose ester resin, and an alkyd resin is used as a binder. It is preferable to use a coloring ink containing a pigment or dye of an appropriate color as a coloring agent. As a method for forming the printing layer, a normal printing method such as an offset printing method, a gravure printing method, or a screen printing method, or a coating method such as a gravure coating method, a roll coating method, or a comma coating method can be used. The printing layer may be provided entirely or partially depending on the purpose of decoration.

The design layer may be composed of a metal thin film layer or a combination of a printing layer and a metal thin film layer. The metal thin film layer is for expressing metallic luster as a design layer, and is formed by a vacuum evaporation method, a sputtering method, an ion plating method, a plating method, or the like. Metals such as aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, and zinc, and alloys or compounds thereof are used according to the metallic luster color to be expressed. When providing the metal thin film layer, a front anchor layer or a rear anchor layer may be provided in order to improve the adhesion between the other layers and the metal thin film layer.

Further, an adhesive layer may be formed on the insert material. The adhesive layer is for bonding an insert material to the molding resin 15 and may be formed as necessary.
As the adhesive layer, a heat-sensitive or pressure-sensitive resin suitable for the material of the molding resin 15 is appropriately used. For example, when the material of the molding resin 15 is an acrylic resin, an acrylic resin may be used. When the material of the molding resin 15 is a polyphenylene oxide / polystyrene resin, a polycarbonate resin, a styrene copolymer resin, or a polystyrene blend resin, an acrylic resin, a polystyrene resin, or a polyamide having an affinity for these resins. A system resin or the like may be used. Further, when the material of the molding resin 15 is a polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, and coumarone indene resin can be used. As a method of forming the adhesive layer, a gravure coating method, a roll coating method, a coating method such as a comma coating method, a gravure printing method,
There are printing methods such as a screen printing method.

Further, the transfer material is a material in which a transfer layer including a release layer, a design layer, an adhesive layer and the like is provided on a base sheet.

As the base sheet, the same one as in the case of the insert material can be used. Further, when the surface of the base sheet has fine irregularities, the irregularities are transferred to the transfer layer, and the surface shape such as matting and hair lines can be expressed.

In order to improve the releasability of the transfer layer from the base sheet, a release layer may be formed over the entire surface before providing the transfer layer on the base sheet. The release layer is released from the transfer layer together with the base sheet when the base sheet is peeled off after the simultaneous molding transfer. As the material of the release layer, a melamine resin-based release agent, a silicone resin-based release agent, a fluororesin-based release agent, a cellulose derivative-based release agent, a urea resin-based release agent,
Polyolefin resin-based release agents, paraffin-based release agents, and composite release agents thereof can be used. Examples of the method for forming the release layer include a coating method such as a roll coating method and a spray coating method, and a printing method such as a gravure printing method and a screen printing method.

The release layer is formed on a base sheet or a release layer. The release layer is a layer that is peeled from the base sheet or the release layer and becomes the outermost surface of the simultaneously molded decorative molded product 16 when the base sheet is peeled after the simultaneous transfer of molding. As the material of the release layer, acrylic resin, polyester resin, polyvinyl chloride resin, cellulose resin, rubber resin,
In addition to polyurethane resins and polyvinyl acetate resins, copolymers such as vinyl chloride-vinyl acetate copolymer resins and ethylene-vinyl acetate copolymer resins may be used. When the release layer requires hardness, a photocurable resin such as an ultraviolet curable resin, a radiation curable resin such as an electron beam curable resin, or a thermosetting resin may be selected and used. The release layer may be colored or uncolored. As a method for forming the release layer, there are a coating method such as a gravure coating method, a roll coating method, and a comma coating method, and a printing method such as a gravure printing method and a screen printing method.

The design layer is a layer for decorating the surface of the simultaneously decorated decorative molded product 16, and may be provided in the same manner as in the case of the insert material.

The adhesive layer is for bonding each of the above layers to the surface of the transfer object. The adhesive layer is formed on a portion to be bonded. That is, if the portion to be bonded is the entire surface, the adhesive layer is entirely formed on the pattern layer. If the portion to be bonded is partial, an adhesive layer is partially formed on the design layer. The adhesive layer may be provided in the same manner as in the case of the insert material.

The configuration of the transfer layer is not limited to the above-described embodiment. For example, when a material having excellent adhesiveness to the transfer object is used as the material of the design layer, the adhesive layer is omitted. be able to.

To obtain a simultaneously-decorated molded product 16 using the simultaneously-decorating mold and the decorative sheet 1 having the above-described structure, the following steps are performed (see FIGS. 2 to 9).

First, the decorative sheet 1 is arranged by the decorative sheet conveying member 11 on the cavity mold 2 having the cavity surface 6 formed in a three-dimensional shape (see FIG. 2).

The decorative sheet 1 includes a decorative sheet conveying member 11
Is transported into the mold. At this time, the decorative sheet 1
Is pulled downward by the decorative sheet transporting member 11 and transported between the three-dimensional frame-shaped clamp member 4 and the cavity mold 2 (see FIG. 2).

Next, the front end of the decorative sheet 1 is fixed by an end face clamp member 9 provided below the cavity mold 2 (see FIG. 3).

At this time, the fixing position of the decorative sheet 1 may be adjusted by using a photoelectric tube sensor or the like so that the pattern of the decorative sheet 1 and the shape of the mold product are aligned.

Next, the decorative sheet conveying member 11 is retracted (see FIG. 4). The end surface clamp member 9 is a decorative sheet 1
Release and move up again.

Next, the feeding of the decorative sheet 1 is fixed, and the fixing of the decorative sheet 1 by the end face clamp member 9 is released (see FIG. 5). The decorative sheet 1 is fixed on the upper side so that the decorative sheet 1 is not unwound or rolled up, and the lower side is a free end. The decorative sheet 1
At least the length along the cavity surface 6 having a three-dimensional shape is sent out.

Next, the cavity surface 6 of the cavity mold 2
Sheet 1 by three-dimensional frame-shaped clamp member 4 along
Is fixed to the cavity mold 2 (see FIG. 6). At this time,
Since the decorative sheet 1 has a free end at the lower side, the decorative sheet 1 does not forcibly be stretched or exerted with an unreasonable tension, and follows the three-dimensional shape of the cavity surface 6 without difficulty.

After the decorative sheet 1 is fixed to the cavity mold 2 by the three-dimensional frame-shaped clamp member 4, the decorative sheet 1 is cut by the decorative sheet cutting means 12 such as a heat cutter provided above the cavity mold 2. (See FIG. 6).

Further, in order to make the decorative sheet 1 easily follow the cavity surface 6, the decorative sheet 1 may be heated by a heating means 14 such as an infrared heater (FIG. 7).
reference).

The decorative sheet 1 may be formed by vacuum forming or pressure forming along the cavity surface 6 (see FIG. 7). The periphery of the decorative sheet 1 is brought into close contact with the cavity mold 2 by the three-dimensional frame-shaped clamp member 4, the space between the decorative sheet 1 and the cavity mold 2 is sealed, and vacuum suction is performed from the suction holes 13 provided in the cavity mold 2. Thereby, the decorative sheet 1 can be vacuum-formed along the cavity mold 2. Further, the decorative sheet 1 is fixed to the cavity mold 2 by the three-dimensional frame-shaped clamp member 4, the core mold 3 is clamped, and compressed air is sent from the core mold 3, so that the decorative sheet 1 follows the cavity mold 2. Pressure molding.

Next, the core mold 3 is closed and the molding resin 15 is injected into the mold (see FIG. 8), and the decorative sheet 1 and the molding resin 15 are integrated to obtain a simultaneous decorative molding 16. (See FIG. 9).

Examples of the molding resin 15 include a polyethylene resin, a polypropylene resin, an acrylic resin, a polystyrene resin, a polyacrylonitrile styrene resin, a polyacrylonitrile butadiene styrene resin, and an alloy resin of PC and ABS containing glass fibers. It is good to use.

After the molding resin 15 has solidified, the mold is opened to take out the resin molded product to which the decorative sheet 1 has been integrated and adhered (see FIG. 9). When the decorative sheet 1 is a transfer material, the base sheet is peeled off. In this way, the simultaneously decorated decorative molded product 16 can be obtained.

The present invention can be applied not only to a two-piece mold having only the cavity mold 2 and the core mold 3 but also to a three-piece mold having an intermediate plate.

[0049]

EXAMPLE A woodgrain panel used for an armrest of a chair was obtained as follows (see FIG. 10).

Using an acrylic film having a thickness of 125 μm as a base sheet, a wood grain design layer and an adhesive layer were formed by gravure printing to obtain an insert material.

Next, the decorative sheet was placed in the cavity of the injection mold by the decorative sheet conveying member. Next, the front end of the decorative sheet was fixed with an end face clamp member, and then the decorative sheet conveying member was retracted.

Then, the feeding of the decorative sheet is fixed and the fixing of the decorative sheet by the end face clamp member is released, and the decorative sheet is formed into a cavity mold by using a three-dimensional frame-shaped clamp member formed in a frame shape of a kamaboko frame. Fixed on top.

Next, a heating means comprising an infrared heater heated to 320 ° C. was arranged at a position 40 mm in front of the insert material, and the surface of the insert material was heated for 5 seconds. The heating means was introduced into the cavity mold only when the heater was heated by driving the air cylinder, and moved out of the mold after heating.

Then, the insert material was stretched by vacuum suction from the outer peripheral cavity surface of the cavity-type molded product and the vacuum suction holes provided in the cavity surface, and three-dimensionally molded along the cavity surface.

Next, the heating means is moved out of the mold, the core mold is closed, and P containing 20% by weight of glass fiber is introduced into the mold.
An alloy resin of C and ABS was injected as a molding resin.

Finally, the mold was opened, and the decorative sheet and the molding resin were integrated to obtain a simultaneously molded decorative molded product.

The simultaneously decorated decorative molded article thus obtained had no wrinkles in the insert material.

[0058]

According to the method for producing a simultaneously molded decorative product of the present invention, a decorative sheet is arranged by a decorative sheet conveying member on a cavity mold having a three-dimensional cavity surface, and then the decorative sheet is formed. The leading end is fixed by the end face clamp member, then the decorative sheet conveying member is retracted, then the feeding of the decorative sheet is fixed, and the fixation of the decorative sheet by the end face clamp member is released. The decorative sheet is fixed to the cavity mold by the three-dimensional frame-shaped clamp member, then the core mold is closed, the molding resin is injected into the mold, and the decorative sheet and the molding resin are integrated to form a decorative simultaneous molded article. As a result, the decorative sheet in the frame of the three-dimensional frame-shaped clamp member can be made to conform to the cavity surface, so that the decorative sheet does not wrinkle while forming. The molded article can be easily obtained.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an embodiment of a mold for simultaneous decorating used in the method for producing a simultaneously decorated decorative molded article of the present invention.

FIG. 2 is a cross-sectional view showing one step of the method for manufacturing a simultaneously decorated decorative molded article according to the present invention.

FIG. 3 is a cross-sectional view showing one step of the method of manufacturing a simultaneously decorated decorative molded article according to the present invention.

FIG. 4 is a cross-sectional view showing one step of the method for manufacturing a simultaneously decorated decorative molded article according to the present invention.

FIG. 5 is a cross-sectional view showing one step of the method for manufacturing a simultaneously decorated decorative molded product according to the present invention.

FIG. 6 is a cross-sectional view showing one step of the method for manufacturing a simultaneously decorated decorative molded article according to the present invention.

FIG. 7 is a cross-sectional view showing one step of the method for manufacturing a simultaneously decorated decorative molded product according to the present invention.

FIG. 8 is a cross-sectional view showing one step of the method for producing a simultaneously molded decorative product of the present invention.

FIG. 9 is a cross-sectional view showing one step of the method for manufacturing a simultaneously decorated decorative molded product according to the present invention.

FIG. 10 is a perspective view showing an embodiment of a simultaneously molded and molded article obtained by the method of manufacturing a simultaneously decorated and molded article of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Decorative sheet 2 Cavity type 3 Core type 4 Solid frame-shaped clamp member 5 Solid frame-shaped clamp member drive source 6 Cavity surface 9 End surface clamp member 10 End surface clamp member drive source 11 Decorative sheet conveying member 12 Decorative sheet cutting means 13 Suction hole 14 Heating means 15 Molding resin 16 Simultaneous decorative molding

Continuation of the front page (72) Terumasa Yamamoto, Inventor, No. 3, Mibuhanaicho, Nakagyo-ku, Kyoto, Kyoto, Japan Examiner, Nippon Photographic Printing Co., Ltd. 58) Surveyed field (Int.Cl. ⁷ , DB name) B29C 33/00-33/76 B29C 45/00-45/84

Claims (4)

(57) [Claims] 1. A decorative sheet carrying member is disposed on a cavity mold having a three-dimensional cavity surface, and the decorative sheet is fixed at its end by an end clamp member. The member is retracted, and then the feeding of the decorative sheet is fixed, and the fixing of the decorative sheet by the end face clamp member is released, and then the decorative sheet is formed into the cavity mold by the three-dimensional frame-shaped clamp member along the cavity surface of the cavity mold. Fixing, then closing the core mold, injecting the molding resin into the mold, and integrating the decorative sheet and the molding resin to obtain a simultaneously-decorated molded product. Production method. 2. The method according to claim 1, wherein the decorative sheet is subjected to vacuum forming or pressure forming so that the decorative sheet is along the cavity surface. 3. The method according to claim 1, wherein the decorative sheet is an insert material. 4. The decorative sheet is a transfer material.
The method for producing a simultaneously decorated decorative molded article according to any one of the above.